MANuAL - Nioex Systems
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1. Q Can finished compost be used as a full substitute for fresh shavings in the BIOVat OT A Experience to date indicates that up to 5096 of the fresh shavings requirement may be substituted with finished compost The long term viability of the process cannot be maintained if fresh shavings are not added because the source of carbon would eventually be exhausted Advantages of recycling finished compost include less fresh shavings required active bacteria and heat are available in the finished compost less finished compost to haul for spreading and speeding up the disappearance of bones Q What about maggots A Generally all kinds of earthworms are beneficial for composting Large sized maggots are particularly beneficial for composting The maggots to be concerned with are the small pale coloured housefly larvae which may present a public health problem Usually the main cause for harmful larvae is lack of shavings inside the 8 OVaLOI or leakage of fluids Therefore it is good practice to maintain a sufficient cover of shavings on top of the carcasses and eliminate any leakage BIOVator The 1 Name for In Vessel Composting User Manual revised June 2010 Q Can the BIOVAtOT be set right on the ground A Yes the BlIOVaLOI may be set on gravel concrete pads or supports ji emi T i poU BIOVator The 1 Name for In Vessel Composting User Manual revised June 2010 MORTALITY COMPOSTING TROUBLE SHOOTING2. GUIDE Probable Symptom Probable Cause Other Clues Suggestions for Remedy Compost fails to heat Failure to maintain temperature Failure to decompose carcass tissues Smell of decaying flesh Pile overheating temperature greater than 150 F 66 C Extremely high temperature greater than 170 F 77 C High temperatures or odours in the curing pile Materials too dry Materials too wet Not enough nitrogen or slow decaying Too much turning Cold weather Compost has dried out Cold weather Too much moisture Improper C N ratio Carcasses layered on top of each other Carcasses placed on the inside walls of the B Ovator Inadequate cover of bulking material over carcass Extended period of low temperature e Insufficient aeration in the bulking agent layer Pile is too large eLow moisture Spontaneous combustion Compost is not stable Pile is too large Cannot squeeze water from material or moisture reading is below 3096 Materials look and feel soggy mixture slumps or moisture reading is more than 6096 C N ratio greater than 50 1 large amount of woody materials Looks very dry Looks soggy Carcass is intact even after 2 3 days of being added to the vator M Pile is too moist vator is more than 75 full Low moisture content pile interior looks or smells charred Higher than 6 ft Add water liquid manure or wet bulking a
3. bacteria will flourish in the higher temperatures and the mass of composting material will be more active and break down faster Above 150 F 66 C the rate of composting will decrease as bacteria are inactivated or even destroyed by the excessive temperature Therefore it is important to monitor the temperature and maintain it at the proper levels during the different stages of composting Generally speaking the temperature inside the B OVaLOT should be above 100 F 38 C and should never be allowed to be lower than this or to exceed 160 F 71 C Unlike outdoor composting this range of temperature is sufficient to kill all pathogens disease and odour causing bacteria Different temperatures may overlap inside the 1OVatOT V with higher levels normally at the front end and lower temperatures close to the discharge opening These varying levels of heat are direct results of the actions of the aerobic bacteria Since these bacteria need oxygen open spaces throughout the BlIOValLOl are important so that air can move through the compost It is estimated that 5 oxygen or more is essential for aerobic action This level is maintained by maintaining 35 to 50 porosity in the compost therefore it is important not to over wet the wood shavings It is also important not to over fill the B OVaLOr more than 75 to allow some aeration through the empty portion of the vessel 3 OPERATING THE BIOVATOR 3 1 Guidelines for First Time Opera
4. guidelines may be helpful in deciding how much rotation is needed e If adding mortality is done regularly with amounts reasonably close to that suggested in the capacities e g adding 200 Ib to 300 Ib daily or 1000 Ib 2 to 3 times a week you may rotate the BIOVaLOT for 4 to 8 revolutions per day about 1 to 2 hours per day This rate is found to be enough for aeration purposes e f you need to add new mortalities and find the loading area overcrowded with old carcasses you may rotate the BIOVaLOr as many times as necessary to clear this area before adding the new carcasses As a rule of thumb with each complete revolution the material inside the BIOVAtOT moves 6 to 12 towards the discharge opening Third Discharging The Compost From The BiOVator It is a good practice not to keep the B OVaLOI more than 75 full with material Therefore once the level of compost reaches the discharge opening at the back of the BIOVAtTOT it should be kept open during rotation As the BIOVATOT rotates finished compost is scooped and pushed through the discharge opening As a rule of thumb with each complete revolution 5 Ib to 10 Ib of compost approximately 0 5 ft to 1 f is pushed through the discharge opening 3 3 Guidelines for Higher Than Average Mortalities When dealing with grow finish operations it is typical to have low mortality weights during the beginning of a cycle with higher mortality weights as t
5. insect larvae or maggots The continuous addition of dry shavings and recycled compost reduces the wet conditions required for egg laying Flies may appear around the B OVatOr during hot weather if doors were left open Odour is generated due to lack of shaving or fluid is leaking from openings If the latter is noticed check the loading and inspection door seals and make sure any leak is collected or cleaned from underneath the BlOVaLOr BIOVator The 1 Name for In Vessel Composting User Manual revised June 2010 PART C THE BIOVatOTr DEVICE 5 THE BlOvator 5 1 The BIOVA LOT Set up Instructions First Selecting the BlOVaALOr Site As long as composting is totally confined inside the B OVaLOr and as long as all doors are sealed properly it can be located in close proximity to a building In selecting the proper location consider these factors e Closeness to the feedstock supply Closeness to a winter exhaust fan e Closeness to power and water outlets e Closeness to wood shaving or any bulk material storage e Leveled ground concrete or gravel are preferred Second Transporting Unloading and Leveling e Exercise extreme caution while transporting and unloading the BIOVaLOL so that neither the exterior shell nor the driving components chains belts motor gearboxes etc are damaged or moved e The BIOVaLOT should be leveled on the ground Avoid any sloping side to side but a sli
6. 0 percent carbon Wood shavings contain 5 percent water 0 5 percent nitrogen and 25 to 50 percent carbon Each pound of carcasses contains an average of 0 30 Ib solid 0 01 Ib nitrogen and 0 075 Ib carbon while each pound of wood shavings contains an average of 0 95 Ib solid 0 005 Ib nitrogen and 0 375 Ib carbon For each pound of carcasses the amount of shavings SH to add is calculated as follows Carbon in 1 Ib of carcass SH x Carbon in 1 Ib of SH C N 25 Nitrogen in 1 Ib of carcass SH x Nitrogen in 1 Ib of SH 0 075 x 1 0 375 x SH 0 01 x 1 0 005 x SH where for each pound of carcass 0 7 Ib of shavings SH needs to be added If the unit weight of wood shavings is 10 Ib f then we add about 0 07 ft of shavings to every 1 Ib of carcass All efforts should be made to use sawdust or wood shavings as bulking materials because of their better physical properties particle size moisture retention etc Also whenever possible use manure and or recycled compost since they contain all of the nutrients needed by the micro organisms as well as the micro organisms themselves which act to ignite the composting process The following table lists approximate quantities that may be used as recipes for proper composting E Wood Shavings Recycled Compost For each 1 Ib of carcass add 0 07 ft a Or 0 035 ft 0 035 ft In addition to providing proper carbon for the mix bulking material also acts as a filter that suppre
7. 16 NOV 04 R238805 Selenium Se Total 15 NOV 04 16 NOV 04 R238805 Tin Sn Total 15 NOV 04 16 NOV 04 R238805 Strontium Sr Total 15 NOV 04 16 NOV 04 R238805 Titanium Ti Total 15 NOV 04 16 NOV 04 R238805 Thallium TI Total 15 NOV 04 16 NOV 04 R238805 Uranium U Total 15 NOV 04 16 NOV 04 R238805 Vanadium V Total 15 NOV 04 16 NOV 04 R238805 Zinc Zn Total 15 NOV 04 16 NOV 04 R238805 Moisture 55 4 0 5 17 NOV 04 17 NOV 04 HSL R239495 Total Kjeldahl Nitrogen 30 4 0 1 o 16 NOV 04 17 NOV 04 JRB R239093 Total Nutrients Complete List Phosphorus P Potassium K Sulfur S Sodium Na Calcium Ca ae 19 NOV 04 R239907 19 NOV 04 19 NOV 04 R239907 19 NOV 04 19 NOV 04 R239907 19 NOV 04 19 NOV 04 R239907 19 NOV 04 19 NOV 04 R239907 19 NOV 04 19 NOV 04 R239907 19 NOV 04 19 NOV 04 R239907 19 NOV 04 19 NOV 04 R239907 19 NOV 04 19 NOV 04 R239907 19 NOV 04 19 NOV 04 R239907 Refer to Reference Information for Qualifiers if any and Methodology Magnesium Mg Copper Cu Iron Fe Maganese Mn Zinc Zn BIOVator The 1 Name for In Vessel Composting User Manual revised June 2010 d ValOrw SAVE THIS CERTIFICATE If your unit needs servicing contact a qualified dealer or sales representative When requesting service please have the model and serial number from the unit readily available If your dealer needs assistance Nioex Systems is available to provide support Fill in the
8. 2 Carbon and Nitrogen Carbon and nitrogen are key compost ingredients While the dead animals themselves supply nitrogen carbon is supplied through the use of carbon rich bulking material such as wood shavings or sawdust which may be used as is Other woody materials such as bark brush tree trimming branches leaves paper and straw should be shredded before use Carbon and nitrogen however must be supplied in proper balance Without such a proper balance called Carbon to Nitrogen or C N ratio microbial growth is retarded the rate of decay slows down and odours can be generated This proper balance varies between 20 1 and 40 1 Lower carbon nitrogen ratios lower than 20 1 may result in emission of ammonia and other odours Higher carbon nitrogen ratios higher than 40 1 may reduce compost temperature and slow down the decomposition process BIOVator The 1 Name for In Vessel Composting User Manual revised June 2010 Carbon to nitrogen ratio is the weight of carbon divided by the weight of nitrogen in the composting material When adjusting C N ratio of a mixture for composting the C N ratio of each added material needs to be considered Example Imagine that we would like to compost hog mortalities with added wood shavings as a bulking agent so that the mixture has a C N ratio of 25 and a water content of 50 percent In this example we assume that hog mortalities contain 65 to 75 percent water 1 percent nitrogen and 5 to 1
9. BIOVator o Nin The 1 Name for In Vessel Composting Setup use and troubleshooting information CONTENTS PART A Composting PART B The BlOvator Composting Process PART C The BlOvator Device Limited Warranty Certificate BIOVator The 1 Name for In Vessel Composting NIOEX SYSTEMS INC 171 Waverly Dr Brandon MB R7B 4A4 WWW nioex com Nioex Systems Inc Shawn Compton scompton nioex com 1 701 370 0782 Nioex Systems USA Inc John V Walser jwalser nioex com 1 507 381 1556 INTRODUCTION The BIOVatOT was developed after extensive research and development work conducted at The Puratone Corporation in Southern Manitoba The main objective of the R amp D work was development of a cost effective alternative to the outdoor composting process The 8 OVaLOI achieves this goal and its introduction into the market was the result of successful operation at Puratone s own farms The BIOVaLOT is a combination of a device and process targeting the quickest transformation of animal carcasses into consistent quality compost at the lowest possible cost and management effort This manual includes the information you may need to successfully operate the B OVaLOI The manual is divided into three main parts Part A general information about composting including an overview of mortality and organic composting and how it differs from regular composting Part B how to compost using the B OVaLOr including m
10. ERVICE GUIDE 6 1 Maintenance Guidelines Appendix I FAQ and Troubleshooting Appendix Il Compost Control Conditions Monitoring Sheet Appendix Ill Compost Lab Analysis Limited Warranty Certificate BIOVator The 1 Name for In Vessel Composting User Manual revised June 2010 PART A COMPOSTING 1 COMPOSTING 1 1 What is Composting Normal decay of any organic material occurs naturally due to the action of micro organisms Some of these micro organisms bacteria and fungi can live without air anaerobic and the rest aerobic need air to survive and carry out the decomposing of organic material General composting of organic matter is a method of speeding up the normal decay processes caused by bacteria and fungi During this process bacteria and fungi decompose organic material in a predominantly aerobic with air environment These micro organisms break down organic material into a stable mixture called compost Brown to dark brown in colour and odourless compost is considered an ideal soil amendment 1 2 Mortality Composting In contrast to general composting mortality composting takes place in both aerobic with air and anaerobic without air zones The animal carcass high in nitrogen with high moisture content and near zero porosity is placed into a mixture of bulking agent high in carbon with high porosity and moderate moisture content creating an inconsistent mixture of materials During this stage called the
11. TICAL REPORT PAGE 4 OF 5 Sample Details Parameters Result Qualifier D L Units Extracted Analyzed By Batch L224759 3 SAMPLE 3 ENDPRODUCT Sample Date 10 NOV 04 Matrix Escherichia Coli MPN gram 10 NOV 04 Salmonella MPN gram 10 NOV 04 10 NOV 04 10 NOV 04 HNT R237806 10 NOV 04 HNT R237805 10 NOV 04 HNT R237807 Silver Ag Total 15 NOV 04 16 NOV 04 R238805 Aluminum Al Total 15 NOV 04 16 NOV 04 R238805 Arsenic As Total 15 NOV 04 16 NOV 04 R238805 Boron B Total 15 NOV 04 16 NOV 04 R238805 Barium Ba Total 15 NOV 04 16 NOV 04 R238805 Beryllium Be Total 15 NOV 04 16 NOV 04 R238805 Bismuth Bi Total 15 NOV 04 16 NOV 04 R238805 Calcium Ca Total 15 NOV 04 16 NOV 04 R238805 Cadmium Cd Total 15 NOV 04 16 NOV 04 R238805 Cobalt Co Total 15 NOV 04 16 NOV 04 R238805 Chromium Cr Total 15 NOV 04 16 NOV 04 R238805 Copper Cu Total 15 NOV 04 16 NOV 04 R238805 lron Fe Total 15 NOV 04 16 NOV 04 R238805 Potassium K Total 15 NOV 04 16 NOV 04 R238805 Magnesium Mg Total 15 NOV 04 16 NOV 04 R238805 Manganese Mn Total 15 NOV 04 16 NOV 04 R238805 Molybdenum Mo Total 15 NOV 04 16 NOV 04 R238805 Sodium Na Total 15 NOV 04 16 NOV 04 R238805 Nickel Ni Total 15 NOV 04 16 NOV 04 R238805 Lead Pb Total 15 NOV 04
12. VatOT With Mortalities e f your operation produces daily mortalities at a rate approaching that specified in the average daily capacity of the BlOVaLOI refer to section 5 4 you may have to load the BIOVaLOr on a daily basis If mortalities are produced on an irregular basis as is the case with most operations you may want to do the loading 2 or 3 times a week instead provided carcasses are not rotting BIOVator The 1 Name for In Vessel Composting User Manual revised June 2010 The BIOVaLOT may even allow you to load only once a week provided that the amount loaded does not exceed the weekly rates specified in the BLOVaLOI weekly capacity Of course you may add any amount of mortality less than that for daily or weekly averages As a rule of thumb you may load the B OValOr with more than its daily capacity as long as weekly capacity is not exceeded e Before loading make sure the BIOVaALOI is not rotating and that power is disconnected e Depending on the size of mortalities you may use one or both loading doors The BIOVatOTr v may be set right on the ground to facilitate loading However for large size mortalities or if the BlOVatOr is placed on a higher elevation you may use a loader to load mortalities e Make sure the section of the BIJOVALOT under the loading doors has enough area to accommodate the mortalities you are about to load If this section is overcrowded shut the doors connect the powe
13. arm RPM 60 Hz RPM 60 Hz RPM 60 Hz RPM 60 Hz duty motor Speed reducer 60 1 Frame 80 Frame 80 Frame 80 Frame 80 Synthetic gear box oil Speed reducer 60 1 Frame 80 Frame 120 Frame 120 Frame 120 Synthetic gear box oil Steel frame Hot dipped galvanize 4 x 4 x 188 4 x 6 x 188 4 x x 188 4 x x 188 thick tubing thick tubing thick tubing thick tubing Nylon roller with 6 dia x 3 wide 3 4 sealed bearings bore 5 500 pound Capacity each 1 Steel drum Spiral welded 2 Inspection door 2 Foam Insulation 1 1 2 2 thick spray on insulation R 8 Cover with SS 304 liner Heavy duty roller chain NN m 0 pL pL oL Control box EEMAC 4X Fiberglass enclosure 120VAC 1 phase 24 hour automated time switch with proximity switch de activation BIOVator The 1 Name for In Vessel Composting User Manual revised June 2010 zz i9 A oO Besides the main components of the BIOVaLOI as listed in the table above the following features may be added e Temperature monitoring data logger PLC based control system for continuous monitoring of temperatures in the vessel e Bone Screener attachment Powder Coated Steel option for screening bones and inorganic material from the finished compost BIOVator The 1 Name for In Vessel Composting User Manual revised June 2010 5 4 BIOVAtOT Models and Capacities There are four main models currently availabl
14. aterial mix requirements how to control the process set up requirements and instructions for first time use and general operation guidelines Part C information about the BIOVaLOr mechanical components including available BiOVaLOr models the capacities and technical specifications of each service and maintenance requirements and your warranty certificate Appendices and Il Frequently Asked Questions recommendations for troubleshooting and composting recording sheet With the BLOVaLOT you are ahead of the rest ready to meet any stringent environmental standards that may restrict operations from using traditional disposal methods By following the guidelines set out in this manual you will be able to transform your mortality and organic wastes into a value added to your operation and in turn recover some or all of its capital investment SAFETY FIRST People who manage on site composting should use precautions just as they would when working with any other soil amendment Minimize direct contact Always wear a mask when opening the B OValOl doors for inspection or loading If discharged compost is dry use the mask to minimize inhalation of particles during handling or spreading Good quality compost however should not be allowed to dry out to that extent People with asthma allergies or serious health problems should not work with soil amendments Working with the 5IOVatOT requires paying attention to the followi
15. ch management is needed to control conditions inside the BIOVatOT and to eventually produce good quality compost in the shortest period of time The following sections present different ways of controlling the composting process 4 1 Temperature and Moisture Control Remember moisture level should be between 40 and 60 Note that the compost should appear moist but not soggy If moisture can be squeezed from a handful of compost material it is usually too wet for effective composting Drier bulking material should be added and mixed with the wet material On the other hand if compost looks dry add water to obtain a damp feel and appearance As a rule of thumb moisture at the first 1 3rd of the BIOVATOr at the loading zone should not exceed 60 while moisture at the middle 1 3rd should be between 40 and 50 Maximum moisture at the end 1 3rd is 40 not more than 6096 between 40 and 50 not more than 40 Moisture Gradient Inside the BIOVATOR BIOVator The 1 Name for In Vessel Composting User Manual revised June 2010 As for the temperature remember that if it falls lower than 100 F 38 C the process slows down If higher than 150 F 66 C there is a risk the composting microorganisms are being destroyed Lower temperature is an indication of lack of shavings high C N ratio or too much moisture It may also be due to lack of oxygen It is therefore important to maintain these parameters within the required li
16. cycled into the B OValLOI when mortality rates have decreased or ended due to the end of the grow finish cycle This will ensure a complete composting process and allow the B OVaLOr to remain active aerobic and ready as producers await the next turn of animals which in some cases may be as long as 6 weeks This procedure will ensure that the BJOVaLOIr maintains constant mortality consumption throughout the entire grow finish process and that all mortalities will be disposed of following the proper Provincial State guidelines Operation for higher than normal catastrophic mortality spikes in grow finish process If a producer experiences mortality that exceeds a normal spike in mortalities a static compost pile should be started in an empty compost bin Producers should put fresh shavings onto the floor of the empty bin 12 18inches and lay the mortalities side by side until that layer is complete Repeat the process for the next layer if needed or cover the pile with the fresh shavings Producers with large animals such as sows may find that 24 inches or more may be required on each layer to contain any leachate from the mortalities Continue this procedure until the end of the grow finish cycle or until mortality rates are within the TIOVatOr s normal loading recommendations Producers may then begin putting the static pile back into the BJOVatOT however they may wish to leave the static pile for 30 days to avoid any leachate o
17. e 8 OVaLOr and creating a large anaerobic mass Fortunately rectifying strategies can be followed to reverse such failures Discussed in the trouble shooting section Q How can tell when compost is cured A If steam is emitting from the discharged pile it is not fully cured You may leave it in the pile for more time or recycle it back into the BIOVaLOI Once pile temperature is down to ambient temperature and compost color is dark brown it is cured Q How large a carcass can be put in the Blovator A Mature sows and boars over 600 Ib can be loaded in the BlIOVaLOI Expect longer composting time for larger carcasses BIOVator The 1 Name for In Vessel Composting User Manual revised June 2010 Q What about contaminants in the finished compost A Again if managed properly the finished compost would have no contaminants Tests conducted on finished compost provided in Appendix Ill where composting conditions were within the limits described in Part B have shown no contaminants such as Ecoli or Fecal Coliform present If proper compost recipes and operational protocol are followed the amp jOVatOT will produce Class A compost Q How do add moisture A The best way to uniformly distribute the water is to use a garden hose with a sprinkle spray head Adding water with a pail would cause some parts to be very wet and others to remain dry Be careful not to over water and create anaerobic conditions
18. e bones from exiting with the compost Bones carry on to their own discharge pile It is estimated that some of the bones may take up to 3 months to break down and disappear If longer periods of time are noticed to break down these bones look for reasons the process is being slowed Many times it is because of not enough shavings in the system m y J L LLLA 4 3 Odour Odour does not generate in a correctly managed BIOVatOTr The presence of odour is an indication of one some or all of the following conditions excessive load at the front part of the vessel too low or high moisture content or lack of adequate shavings covering the carcasses Odour can also be noticed if partially decaying carcasses are added to the compost Odour is more noticeable when opening the loading doors inspection doors or the discharge opening It is unlikely to notice such odour outside The BIOVatOT unless doors have been kept open for long periods of time with such mismanaged conditions existing Monitoring the compost temperature is a good check to avoid odour Temperatures that are too low or do not increase after loading indicate a problem with the process and forewarn of impending odour 4 4 Flies Insects Vermin and Scavengers Due to the complete confinement of the compost mixture inside the b OVaLOI scavengers and vermin do not exist The heat produced combined with the turning of the B OVaLOr also prevents development of
19. e for the 5jOVatOT 316 418 430 and 442 These models vary in sizes and capacities to process organic material The capacity of the B OVaLOI is defined as the maximum amount of organic material that can be processed into compost within optimum time limits and with the highest possible consistency The amount of organic material is based on weekly averages a facility may produce under normal operation Estimated Estimated Estimated Example Hog Operation Blovator Average Average Average Diameter Length Annual Weekly Daily Capacity Ib Capacity Ib Capacity Ib Less than 45 000 Less than 1 250 65 000 2500 finishers 200 sow farrow to finish 525 sow farrow to wean 4000 finishers 300 sow farrow to finish 800 sow farrow to early wean 10000 finishers 1500 sow farrow to finish 2600 sow farrow to early wean 130 000 to 65 000 to 2 500 7500 finishers 130 000 750 sow farrow to finish 1500 sow farrow to early wean Estimated Average Capacities are equivalent for Swine Poultry and Processing Plants Pre processed organic waste and fish waste have capacities of up to two times these rates 6 MAINTENANCE AND SERVICE GUIDE 6 1 Maintenance Guidelines In order for the BIOVatOT to run properly the following checks need to be made routinely e Gearboxes should be kept full of synthetic gear oil There is a sight glass or a plug located on the side of the gearbox The oil level should be some
20. ed with outdoor composting Mortalities or organic waste are mixed with measured quantities of wood shavings and occasionally water While anaerobic activities are underway inside carcasses aerobic micro organisms are also in action throughout the vessel breaking all organic matter down into humus like material that is consistent in quality and can be used as a soil enhancing agent Unlike outdoor composting the BIOVatOr offers a highly controlled process which accelerates the natural process of decaying Regardless of outdoor conditions the composting temperature inside the BIOVATOT is always higher than 100 F 38 C In less than 7 days in summer 14 days in winter the bulk of the composting process is finished inside the 11OVatOT and the operator can discharge and pile it up or recycle it back with the addition of more mortalities and less wood shavings 2 MATERIAL REQUIREMENTS USING MORTALITIES AS A FEEDSTOCK EXAMPLE 2 1 The Recipe To survive and effectively do their intended job micro organisms that speed up the decaying process of carcasses need e Carbon and Nitrogen e Moisture e Heat e Aeration While composting may eventually occur naturally the BLOVaLOI process utilizes proper mixing of those ingredients so that composting occurs rapidly minimizing odours and nuisance problems and yielding good quality compost The following presents the recipe that must be followed for successful composting 2
21. erly managed and when carcasses inside the 3 OVaLOI are totally covered with enough sawdust straw odours are sufficiently suppressed or absorbed Using insufficient less than 6 cover at any time bulking material is the single greatest factor causing odours in and around the facility BIOVator The 1 Name for In Vessel Composting User Manual revised June 2010 Q Is cutting dismembering required for large carcasses A No However if facility managers wish to speed up the process and have the means to do it they may put a few holes or cuts in the carcasses It should be noted large carcasses 400 600 Ibs would take longer to decompose than smaller ones Q What about diseases flies and pathogens A The high compost temperatures cover of sawdust and full enclosure of the B OVator are sufficient to restrict pathogen survival and fly incubation No disease outbreaks attributable to composting have been documented to date Q What are other sources of bulking materials A Any granular organic material with high carbon content should work Long fibrous material such as hay or cornstalks may be used Lack of absorption however may be more evident with these materials because of their poor moisture retaining qualities Shredded paper has been used at some facilities Q What is the composition of the compost A Generally speaking compost includes the following nutrients Nitrate Ammonium Calcium Phosphorous Potass
22. for prolonging the BIOVatOTr v s life e Rubber seals Make sure rubber seals are fastened to the doors at all times Loosening these seals will allow liquids to seep through the doors e Removing falling material bulking material remnants of loaded mortalities mixed with moisture could fall on the steel skid door frames chains and the rest of the driving components It is a good practice to clean underneath the BJOVatOT and remove these falling materials regularly These materials would contribute to corrosion of steel parts as well as accumulation of flies and maggots e Stainless steel outer shell check regularly for damage Repair cuts or openings to prevent moisture from entering the foam space which could cause damage in cold conditions BIOVator The 1 Name for In Vessel Composting User Manual revised June 2010 APPENDIX I FREQUENTLY ASKED QUESTIONS AND TROUBLESHOOTING GUIDE MORTALITIES COMPOST MANAGEMENT Frequently Asked Questions Q Does the composting action continue during winter months in cold climate areas A If started during summer or early winter not later than November composting would continue during the winter months provided thicker layers of woodchips are added on top of the carcasses after turning and hording is used to shelter the 5jOVat OT The barn s warm exhaust air may be used to keep the heat inside the BjOVatOT above 100 F 38 C Q Does it stink around the BIOVatoOr v A When prop
23. gent Add dry bulking agent e Add more carcasses perhaps cut or poke holes in them Stop rotation until heat is back Use external heat add highly degradable materials manure Open pile and add water or manure Ensure adequate cover with bulking agent and avoid adding frozen carcasses use external heat Add fresh bulking agent to absorb moisture Improper mix of ingredients or very old shavings sawdust or straw Make sure there is 4 6 of bulking material between layers Fill at least 6 of space between carcass and inside wall of the vator with shavings Cover carcass with at least 1 ft of bulking material e Add manure and partially cut carcasses and cover with ft of bulking material Add drier material and start rotation until well mixed with wet material e Start discharging e Add water e Start rotation and discharging add water to charred or smoldering sections Turn and mix pile until the temperature and moisture are within limits or recycle back into the vator M Decrease pile size Ammonia odours coming from High nitrogen level or pH e Add more sawdust the curing pile Rotten eggs odours coming from the curing pile Anaerobic conditions Inadequate cover over carcasses Low pile temperature Add dry shaving and mix Maintain 6 of cover Fly problems Compost does not reheat even after turning Compost contains lumps of materials and large b
24. ght incline towards the discharge is acceptable to keep accumulation of liquids at the loading zone Leveling will also prevent structural or mechanical damage due to impact when loading mortalities and to long term stresses e Avoid placing the BIOVatOT skid right on the ground Prevent direct contact with wet conditions and subsequent rusting by lifting the skid off the ground using wood ties or 4 by 4 strips e f placed on concrete blocks piles or any similar supports the BIOVaLOI frame must be supported below the end truss and below each set of rollers to prevent any excessive deflection of the skid e Avoid stopping the BIJOVatOT grum with the doors at the bottom If full excessive weight may damage door latches Fluids may also leak in this position 5 2 Description of the Device The BIOVAatOF is a device and process for disposing of organic waste material While Part B described the process this part of the manual covers the equipment details The device is a stationary composting vessel The composting vessel consists of a slowly rotating steel drum that has steel paddles mounted on the inside walls The paddles are mounted in a spiral shaped pattern with varying spacings to allow material to move in one direction at a certain speed inside the vessel The vessel has loading inspection and discharge openings The loading openings are used for loading car casses and bulking material Bilovator The 1 Name for In Vesse
25. he animals get larger Mortality amounts increase throughout the grow finish period and during disease breaks occasionally creating capacity requirements in excess of the BIOVALOT s recommended daily capacity However the BIOVatOrT has been demonstrated to handle mortality weights exceeding the weekly capacity for short periods of time during high mortality peaks Bilovator The 1 Name for In Vessel Composting User Manual revised June 2010 In order to effectively utilize the OVatOT and comply with Provincial and State requirements for maintaining a temperature of 130 F 55 C for a minimum of 5 days the following procedures will be applied Standard Operations for normal spikes in mortality during the grow finish process Continue to fill the BIOVAatOT to its rated capacity of mortality As capacity requirements increase producers should increase the daily rotations of the B OVaLOI up to 24 revolutions which will move the product through faster and allow as much as double the daily recommended loading rate to be placed in the BIOVatOT Depending on the length of time and amount of overloading above weekly capacities the temperatures in the BLOVaLOT may drop below the 130 F 55 C standard which may result in an end product that is not in a mature state and will not have met the 5 days 130 F 55 C requirement At this point producers should store this product in a bin with additional fresh shavings so that it can be re
26. ic compost piles were used they should be recycled back into the BIOVAtOT during this period It is important that producers clean out bins prior to new production cycles or during low mortality periods in order to be prepared for unexpected spikes in mortality 3 4 Winter Operation As long as it is managed properly composting continues consistently throughout the year However the process can sometimes be quickly disrupted during cold weather due to mismanagement This disruption may manifest itself in the form of compost temperature dropping below that required or even total failure Therefore the BIOVaLOT offers its users a unique advantage over other composting systems Besides the R8 foam insulation preventing loss of heat from the inside and the full enclosure of the vessel the BIOVatOr can be set up close to any winter ventilation exhaust fan The warm and moist air exhausted from the barn can greatly contribute to maintaining conditions in and around the 8 OValOr within reasonable levels BIOVALOT s can be enclosed in buildings with proper ventilation to aid in cold climate operation but it is not a necessity Protection from prevailing winds is all that is required for continued operation of the B OVator year round 4 CONTROLLING COMPOSTING CONDITIONS Unlike any other mortality disposal methods composting with the BIOVaLOr is a forgiving process as long as a minimum level of management is provided Su
27. ing of heat when opening any of the BIOVaLOI doors etc When measuring take the average of three readings Record values on a data sheet similar to that shown in Appendix ll measuring temperature amp moisture in loading zone measuring temperature amp moisture in middle 1 3rd section measuring temperature amp moisture at the end 1 3rd section Monitoring and recording temperature and moisture ensures that the composting process is progressing properly and will alert you to any problems in the process These problems and how to rectify them are listed in Appendix troubleshooting The BIOVALOT also comes with two thermometers installed in the wall of the drum see photo below to give the operator a quick view of the temperatures at the loading and inspection zones These are in place to alert the operator of any drastic changes in operating temperature that could indicate a possible problem These are a guideline only and do not necessarily represent the actual temperatures in the center of the compost mix Typically temperatures will be higher in the center than the readings on the surface thermometers BIOVator The 1 Name for In Vessel Composting User Manual revised June 2010 4 2 Bones Some bones such as large skulls teeth or ball joints may not be fully composted in the same short time as flesh and muscles The BIOVatOr has an optional bone screener attachment see photo below that prevents th
28. installation date and model and serial numbers of the unit in the space provided below and retain this Limited Warranty for your files GENERAL TERMS The term of this Limited Warranty is one 1 year on workmanship two 2 years on motor and gearboxes and ten 10 years pro rated on inner steel barrel against perforation due to corrosion in normal use The use of acid material will cancel this warranty All drive components are under warranty from the manufacturer The warranty commences on the date the unit was invoiced to the customer as shown on the customer invoice Installation Date Model No Serial No Nioex Systems Inc 171 Waverly Drive Brandon MB R7B 4A4 D BIOVator The 1 Name for In Vessel Composting User Manual revised June 2010 NOTES BIOVator The 1 Name for In Vessel Composting User Manual revised June 2010 BIOVator The 1 Name for In Vessel Composting User Manual revised June 2010
29. ium Magnesium Iron Manganese Sodium and other salts The amounts of these nutrients in the compost will vary according to the age of the compost and management of the process Q What is the compost material used for A If properly managed the qualities of the finished compost would resemble that of peat moss Therefore compost can be used as a peat moss substitute in greenhouse and landscape applications such as e For improvement of organic matter content and fertility of soil e For increasing water holding capacity e For increasing aeration and drainage of clay soils e For erosion protection of lagoon banks BIOVator The 1 Name for In Vessel Composting User Manual revised June 2010 Q Are there any additives that can be used to speed up composting even further A Some composting experiments where inoculants were used have been documented The results were inconclusive in showing any advantage from use of such inoculants Q Does composting fail A If not managed properly compost may not heat enough particularly in wintertime and may produce odours in summer Composting is a biological process that depends on providing nutrients and an environment favorable for bacterial decomposition Common mistakes are e Failure to provide enough shaving or bulking material inside the B OVaLOI to provide for the bio filter and to maintain an appropriate carbon source for the system to operate over time e Overloading th
30. l Composting User Manual revised June 2010 The vessel is supported on side nylon rollers and a front pillow block Nylon rollers are supported by a steel skid The vessel rotates at a speed of 3 revolutions per hour or 20 minutes per revolution approximately 5 3 BlOVator Components amp Technical Specifications BIOVator The 1 Name for In Vessel Composting User Manual revised June 2010 Technical Component Description Specification Model BIO316 Model BIO418 Model BIO430 Model BlO442 Mild steel 1 4 thick 16 feet long 18 feet long 30 feet long 42 feet long Two part epoxy 3 dia 4 dia 4 dia 4 dia coated 17 1 2 24 opening no door no door 1 door 2 doors SS 304 construction 1 vented Foam insulated Nitrile seal 1 3 4 x 3 4 Ratchet type locking device 3 Steel channel 6 x 10 5 pounds per 1 channel 1 channel 2 channels 3 channels foot Welded to the drum Hot dipped galvanize Loading door 24 x 90 opening 2 1 door 2 doors 2 doors 2 doors doors SS 304 construction Foam insulated Nitrile seal 1 3 4 x 3 4 Ratchet type locking device Steel sprocket Bolted to center of Fit 60 chain Fit 100 chain Fit 100 chain Fitz 100 chain the loading end of 99 teeth 89 teeth 89 teeth 89 teeth the rotary vessel Pillow block SAP208 24 for HCP211 32 for HCP211 32 for HCP211 32 for 1 5 shaft 2 shaft 2 shaft 2 shaft Electric motor 110 volts single 0 5 HP 1725 1 HP 1725 1 HP 1725 1 HP 1725 phase Baldor f
31. mits Unlike outdoor composting the 3IOVaLOT has the advantage of rotation that allows the compost to aerate and maintain the temperature within the required limits Turning the BIOVatOT for 5 to 10 turns every day achieves that It is also suggested that not more than 75 of the BIOValOr is kept full with compost material As a rule of thumb temperature at the first 1 3rd of the BI OVaLOr at the loading zone should be above 100 F 38 C Temperature at the middle 1 3rd should be above 110 F 43 C The temperature of the compost or material at the back 1 3rd may be between 80 F 27 C and 90 F 32 C at least 110 F at least 100 F between 80 F and 90 F BIOVator The 1 Name for In Vessel Composting User Manual revised June 2010 There are a number of ways to monitor both the temperature and moisture inside the BIOVaLOI The most effective method is to use a 32 hay bale tester The probe can be used to measure both temperature and moisture of the compost The frequency of monitoring temperature and moisture is dependent on o The frequency of adding mortalities It is good practice to measure temperature and moisture every time before you add mortalities o The experience of the operator As the BLOVaLOT operator gains hands on experience with compost and its conditions requirements measuring of temperature and moisture can be done bi weekly or monthly unless problems happen e g foul odour flies no sign feel
32. ng Driving system cover The BIOVatOT comes with safety guards to all mechanical parts Make sure the motor gearboxes pulleys belts chains and rollers are well covered Loading of waste and shavings If using a front end loader make sure not to hit the BjOVaLOT V or any part of its supporting structure Opening of doors Loading and inspection doors are heavy Make sure you are standing on a solid and stable support while opening or closing these doors BIOVator The 1 Name for In Vessel Composting User Manual revised June 2010 TABLE OF CONTENTS INTRODUCTION SAFETY FIRST PART A COMPOSTING 1 COMPOSTING 1 1 What is composting 1 2 Mortality composting PART B THE BIOVALOLr COMPOSTING PROCESS 2 MATERIAL REQUIREMENTS 2 1 The Recipe 2 2 Carbon and Nitrogen 2 3 Moisture Content 2 4 Heat and Aeration 3 OPERATING THE BiOvator 3 1 Guidelines for First Time Operation 3 2 Guidelines for Regular Operation 3 3 Guidelines for Higher Than Average Mortalities 3 4 Winter Operation 4 CONTROLLING COMPOSTING CONDITIONS 4 1 Temperature and Moisture Control 4 2 Bones 4 3 Odour 4 4 Flies Insects Vermin and Scavengers PART C THE BIOVALOr DEVICE 5 THE BIOVatOr v 5 1 BIOVAaLOT Set up Instructions 5 2 BIOVatOr Description of the device 5 3 BIOVatOr Components amp Technical Specifications 5 4 BlOValOr Models and Capacities 6 MAINTENANCE AND S
33. ones texture is generally not uniform Poor sanitation conditions Failure to achieve desired conditions Too high moisture Low moisture Composting near completion Poor mixing of materials or insufficient mixing turning for materials ready for discharging Active composting not complete BIOVator The 1 Name for In Vessel Composting Cannot squeeze water from material Approaching expected composting time period Visible raw material lumps of compost Curing pile heats or develops odours Check for leaks from the doors keep the surrounding site clean and free of garbage or debris Follow as above Add more cover of bulking material Add water and mix None required you may discharge e Scoop and recycle back into the vator M Increase retaining time inside the BlOvator or improve composting conditions User Manual revised June 2010 COMPOST CONTROL CONDITIONS MONITORING SHEET APPENDIX Il Name of Weather Pile Temperature amp Moisture Approx Gal of water Approx Operator Condition weight of bulking weight of mortality Discharge Pile ALLE AUT o o LL MEN Inspection Zone F C Loading Zone F C material added o o o o o 7 E or organic User Manual revised June 2010 BIOVator The 1 Name for In Vessel Composting APPENDIX II HOG COMPOST ENVIRO TEST L224759 CONTD ANALY
34. primary stage the carcass degrades through the action of anaerobic bacteria and micro organisms releasing fluids and gases which diffuse away from the carcass and enter the aerobic zone In the aerobic zone aerobic bacteria and micro organisms degrade the fluids and gases into carbon dioxide CO2 and moisture H2O This action results in the emission of heat The composting complete transformation of the mixture including the decomposed carcass which may include a few bones into a neutral and odourless dark compost must undergo a curing process to complete the transformation This curing process is called the secondary stage Throughout the process the compost is turned to allow the aerobic bacteria to finish their job The composting is successfully completed when you can hold a handful of material and smell no foul odour in it Squeeze no moisture from it and feel no heat coming out of it This form of composting conserves the nutrients contained in dead animals preserves the environment and reduces odours and nuisance associated with storing or incinerating carcasses BIOVator The 1 Name for In Vessel Composting User Manual revised June 2010 PART B THE BI OVatOT COMPOSTING PROCESS Besides the economic advantage the 8 OVaLOIr offers composting with the BIOVaLOI is simple to manage and results are guaranteed The BlIOVaLOI offers a continuous composting process throughout the year and eliminates problems associat
35. r and start rotating the BLOVaLOT for as many rotations as are needed to push the material forward and away from the loading area As a rule of thumb do not load additional mortalities unless the area under the loading doors is less than 50 full e Add part of the required shavings or a combination of shavings and recycled compost on top of carcasses already existing in the BIOVaLOr before adding the new mortalities e Add the new mortalities and then cover with the balance of the required shavings or a combination of recycled compost and shavings e If water is required add uniformly If no calculations were done as a rule of thumb add a 2 to 4 layer of shavings or a combination of shavings and recycled compost 50 50 on top of old carcasses Then cover the new loaded mortalities with a 6 to 8 layer of shavings or a combination of shavings and recycled compost 50 50 or make sure that the flesh of different carcasses are separated and totally hidden in the bulking material new loaded carcasses old carcasses Bilovator The 1 Name for In Vessel Composting User Manual revised June 2010 Second Turning The BIOVALOr The reasons for turning the BIOVaLOT are 1 Aeration so that porosity of mix is enhanced and aerobic bacteria get enough oxygen to survive and do their job properly 2 Moving materials towards the discharge opening 3 Discharging compost from the discharge opening The following
36. r odor issues Following this procedure will ensure that the B OVaLOI maintains constant mortality consumption through the entire grow finish and that all mortalities will be disposed of following the proper Provincial State guidelines Example situation Poultry or Swine Operation with a 42 500 Ib day 3500 Ib week capacity biOVator during high mortalities or end of a grow finish cycle As producers anticipate mortalities above 3500 Ib week begin increasing revolutions from the standard rate of 12 revolutions per day to 14 when you approach 500 Ib day Note The rate you increase the rotations depends on how soon you anticipate higher mortality rates Don t wait to increase revolutions until you are over the standard daily capacity For example At 400 500 Ib day Rotations would remain at 12 revolutions normal Anticipating 500 pounds a day increase to 14 revolutions Anticipating 600 pounds a day increase to 16 revolutions Anticipating 700 pounds a day increase to 18 revolutions Anticipating 800 pounds a day increase to 22 revolutions BIOVator The 1 Name for In Vessel Composting User Manual revised June 2010 Anticipate higher mortality rates and speed up the B OVaLOIr in order to make additional room as needed As mortalities decrease reduce the revolutions accordingly back to 12 14 per day and begin recycling any compost that did not complete the minimum of the 5 days at 130 F 55 C requirement If any stat
37. sses odours generated by the decaying process and reduces accumulation of flies and maggots Therefore as a rule of thumb carcasses should be wrapped completely with a 6 to 12 layer of such material Bulking material should be stored as close as possible to the BIOVaLOI If an empty bin or a shed is available use it for storage If stored outdoors use tarps or any impervious plastic sheets to cover the pile Moist shavings or sawdust is better than bone dry material since moisture is uniformly distributed in wet material and it reduces the amount of water to be added BIOVator The 1 Name for In Vessel Composting User Manual revised June 2010 2 3 Moisture Content A proper moisture level is very important for proper composting Like all living things bacteria need water to survive To encourage bacterial growth and rapid composting the mixture should have 40 to 60 moisture Lower moisture contents less than 4096 will result in slow decaying of mortalities Higher moisture contents above 60 results in filling all pores needed to provide oxygen with moisture replacing aerobic bacteria with anaerobic ones that produce high odours and grow much more slowly than aerobic bacteria Hence the composting rate becomes much slower Example To precisely calculate the amount of water needed for composting let us consider the above example again where the water content is the weight of water in the carcass and shavings di
38. tion First Testing e Make sure all doors open and close freely and that all bolts for hinges and locks are secured with the proper nuts and washers e Make sure all chains and rubber belts connecting the motor and gearboxes to the vessel are attached properly e Make sure the pillow block is secured to the vessel shaft e Make sure the nylon casters are placed properly inside the channels e Make sure the motor is connected to the correct power outlet e Close all doors turn power on and observe rotations for at least 2 revolutions before loading for the first time Second Preparing the B1OVatOr for first time use e Add 8 to 10 layer of shavings at the bottom of the BIOVatOT preferably along the whole length of the vessel or at least at the loading door section SO eta at etal et LEE EET ARE AREE SETETE 9 to 10 i VI man a aa farafaretsc 8 to 10 of shaving or Vds nn HEEL recycled compost Bilovator The 1 Name for In Vessel Composting User Manual revised June 2010 TLETT Zsu n ni lVoisten the shavings not excessively just enough for the shavings to absorb moisture without getting mushy or fully saturated 8 to 10 of shaving or recycled compost e Add feedstock Make sure not to overcrowd the loading area Genes 4 to 6 of shaving or recycled compost e Add another layer of shavings 4 to 6 on top of feedstock Make sure all flesh is co
39. vered amp to 10 of shaving or IEEE ks a recycled compost BIOVator The 1 Name for In Vessel Composting User Manual revised June 2010 e Again add enough water to the shavings to moisten it without over soaking it Depi Senepemenes b 4 to 6 of shaving or 1j yp ice recycled compost Aa F J eae ire tte oie P Bet Met Set Meh Met ml Lee heel ec hu Re Pe E Pr fai yetyetiefyefpefy ef efyeLy ef T e Close doors and leave for 4 5 days or until temperatures reach 100 F 38 C after which you may begin regular operation 3 2 Guidelines for Regular Operation In 4 to 5 days from first loading of the BIOVatOr or when temperatures reach 100 F 38 C regular operation may commence The composting process begins by loading feedstock and adding properly calculated moisture and bulking material then rotating the B OVaLOr Continue monitoring heat and moisture of the compost Adjustments to amounts of bulking material and or moisture are done according to levels of heat inside the BlOVator Controlling these conditions along with the slow movement of material drastically reduces the time of composting Material reaches the discharge end in less than a week and it is then ready for discharge Part of the discharged material is recycled back into the BJOVatOT while the rest is stockpiled until ready for use The following are general instructions for maximum results of the BIOVaLOr First Loading The 5j0
40. vided by the total weight of the composting material The following relationship will give 4096 moisture content in both the carcass and the shavings Water content 1x0 65 0 7 x 0 05 x100 1 0 7 Since carcasses have zero porosity when freshly added to the BlIOVaLOr an equivalent amount of water to that contained in the carcasses plus an additional 10 must be added to the shavings so that the total mixture has enough moisture content 5096 for bacteria to begin composting This amounts to 0 5 liter of water for each 1 Ib of carcass and 07 ft of wood shavings The following table shows recommended values of water added with different recipes to achieve target moisture content of 5096 Wood Shavings Recycled Water Compost For each 1 Ib of 0 07 ft 0 5L carcass add Or si 0 035 ft 0 035 ft 0 25 L 0 50L These are start up values As a rule of thumb once the composting process has started within the vessel the moisture released from the mortalities is sufficient to maintain the required 40 to 60 moisture level in the mix BIOVator The 1 Name for In Vessel Composting User Manual revised June 2010 2 4 Heat and Aeration The temperature of compost is a very important indicator that the process of composting is working properly Warm mortalities degrade much more rapidly than cold ones As bacteria begin to break down the organic materials heat is generated As the compost warms up different
41. where between the top and bottom of the sight glass The large gearbox should be filled to the top shaft level to allow proper lubrication e The drive system contains two chains A 50 series chain used to connect the two gearboxes together and a 60 100 series chain used to turn the main drum Both chains have adjustable idler sprockets to keep them tight Figures 1 amp 2 These idler sprockets may need to be adjusted over time to maintain proper tension in the chains The chains should also be lubricated annually to prevent premature wear BIOVator The 1 Name for In Vessel Composting User Manual revised June 2010 Figure 1 50 series idler sprocket Figure 2 100 series idler sprocket e The drive system also has a v belt connecting the motor to the first gearbox This belt may need to be tensioned periodically Loosening motor bolts Figure 3 and sliding the motor horizontally can tension this belt Figure 3 motor bolts Figure 4 support roller nylon caster BIOVator The 1 Name for In Vessel Composting User Manual revised June 2010 Figure 5 2 bearing in pillow block Figure 6 1 7 bearings with chain coupler e The support roller wheels Figure 4 are maintenance free with stainless steel sealed bearings The drive bearings Figures 5 amp 6 have been greased from the factory but should be greased at least annually In addition to the above the following maintenance guidelines are recommended
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